Mattress structure



March 7, 1961 J. J. WETZLER MATTRESS STRUCTURE 4 Sheets-Sheet 1 Filed May 23, 1957 March 7, 1961 J. J. WETZLER MATTRESS STRUCTURE 4 Sheets-Sheet 2 Filed May 23, 1957 March 7, 1961 J. J. WETZLER MATTRESS STRUCTURE Filed May 23, 1957 4 Sheets-Sheet 3 fi 7 j. 9 j. n m m? w l M v w W R w! J N v. w i o. was; Em Iw i 5 m 5? 5 m ii i March 7, 1961 J. J. WETZLER MATTRESS STRUCTURE 4 Sheets-Sheet 4 Filed May 23, 1957 5? J55 J55 @419 J20 J53 120 JOZ ' INVENTOR. 145147 JM MATTRESS STRUCTURE Justin J. Wetzler, Evanston, IlL, assignor to The Englander Company, Inc., Chicago, Ill., a corporation of Delaware Filed May 23, 1957, Ser. No. 661,122 I 7 Claims. c1. s-s4s This invention relates to a mattress structure and to method and apparatus for making the same. Specifically, the invention pertains to methods and structures for joining together parts of a mattress cover or ticking assembled around a mattress body.

Tickings or covers of conventionl mattresses are made of parts joined by one of several methods described hereinbelow.

In better grade mattresses the ticking or cover is made up of parts which are initially arranged around the mattress body and thereafter sewed together at the mattress edges. Specifically, the margins to be sewed together are each folded back upon themselves, the folded margins are then superposed, one on the other, a piece of tape is folded around the superposed margins, and the assembled parts are sewed together by stitching extending therethrough. A conventional roll edge machine is used for this stitching which is initiated at one point of the mattress and thereafter continued progressively around the mattress edge until the initial starting point is reached. A high grade well tailored mattress can thus be produced, but not without difliculty, for, as the sewing of the ticking of the mattress nears completion, it is diflicult to pull the ticking tight at the joint being sewed to form a tight fitting and well tailored seam or joint all away around the mattress.

Another method is followed in making cheaper mattresses. In making such mattresses, the entire ticking or mattress cover is sewed together with ordinary sewing machines in the sewing department of the factory in the form of an envelope open at one end. The mattress body is then tucked into the envelope from this open end, and the open end is closed. It is much easier to sew the ticking with ordinary sewing machines in the sewing department, apart from the mattress body, than it is to form a seam or joint with a roll edge machine with the ticking or cover disposed around the mattress body. However, in the filling operation wherein the mattress is tucked into the envelope-shaped ticking or cover, the padding associated with the mattress body frequently becomes disarranged. Further, in general, this method provides a lower quality structure with a less tailored and less pleasing appearance.

According to the present invention, the mattress covering or ticking is made in two halves which are assembled with the mattress body. Each half of the mattress covering or ticking can be made in the sewing department of a mattress factory with ordinary sewing machines. Assembly of the two mattress covering or ticking halves and the mattress body is easily accomplished without disarranging any part thereof. The opposed margins of the two halves of the covering or ticking are joined together by means of an inner and an outer tape disposed, respectively, to underlap and to overlap the margins of the opposed halves of the mattress covering or ticking. The resulting three-ply structure extending around the mattress is held together by buttons or studs extending from one of the tapes through the other tape, the ticking along the line 1919 of Fig. 16;

Patented Mar. 7, 1961 margin interposed between the two tapes being either pierced by or wrapped around the studs or buttons. Thus, a quality tailored mattress structure of pleasing appearance is obtained.

Other features of the present invention will become apparent from the following, description and the appended claims as illustrated by the accompanying drawings showing, by way of examples, methods and structures according to the present invention, and wherein:

Fig. 1 is a perspective view of a mattress including a cover or ticking made up of two halves joined together;

Fig. 2 is a diagrammatic cross sectional view on a re duced scale taken along the line 22 of Fig. 1 and showing an initial stage in the assembly of the mattress of Fig. 1;

Figs. 3-5 are views similar to Fig. 2 showing subsequent stages of assembly;

Fig. 6 is an enlarged transverse vertical cross sectional view, with parts broken away, showing the two opposed margins of the ticking halves of the mattress of Fig. 1 before being joined together by means of an outer tape carrying buttons and an inner perforated tape;

Fig. 7 is an enlarged cross sectional view similar to Fig. 6, with parts broken away, showing the assembled joint;

Fig. 8 is a view similar to Fig. 7 but showing an inner tape carrying buttons and an outer perforated tape;

Fig. 9 is a plan view of the perforated tape shown in Figs. 6-8;

Fig. 10 is a plan. view of the button carrying tape shown in Figs. 6-8;

Fig. 11 is a side elevation of a semi-automatic apparatus according to the present invention for making mattresses of the type disclosed hereinabove;

Fig. 12 is an end view of the apparatus of Fig. 11;

Fig. 13 is an enlarged fragmentary cross sectional view taken along the line 1313 of Fig. 12;

Fig. 14 is a view taken along the line 14-14 of Fig. 13;

Fig. 15 is a fragmentary perspective view of the device of Figs. 11-14, with parts broken away, showing the formation of a joint between the two halves of the mattress covering or ticking;

Fig. 16 is a fragmentary cross sectional view taken along the line 1616 of Fig. 15;

Fig. 17 is a fragmentary cross along the line 1717 of Fig. 16;

Fig. 18 is a fragmentary cross along the line 1818 of Fig. 16;

Fig. 19 is a fragmentary cross sectional view sectional view taken sectional view taken taken Fig. 20 is a fragmentary cross sectional View taken along the line 2020 of Fig. 16;

Fig. 21 is a fragmentary cross sectional view along the line 2121 of Fig. 13;

Fig. 22 is a fragmentary perspective view showing a corner of a mattress made by the method and apparatus illustrated in Figs. 11-21; and

Fig. 23 is a cross sectional view taken along the line 2323 of Fig. 22.

Referring now to Fig. 1, a mattress generally indicated at 2 includes a cover or ticking made as two separate halves generally indicated at 16 and 12. As shown in Figs. 1 and 6, the parts 10 and 12 of the mattress case or cover include, respectively, body sheets 14 and 16 and strips 18 and 20 defining a boxing or sidewall for the case. The edges of the strips 18 and 20 are opposed to and slightly spaced from each other. The strip 18 is joined to the body sheet 14 by any suitable desired seam 22, and the strip 20 is joined to thebody sheet 16 by a seam 24.

As shown in Figs. 26, the mattress 2 is assembled by first disposing one cover part 12 over the mattress taken body 26 (see Fig. 2), then inverting the resulting structure (see Fig. 3), depositing the other cover part on the mattress body (see Fig. 4), and joining the opposed margins of the two mattress parts 10 and 12 by means of outer and inner tapes 28 and 38, respectively, overlapping and underlapping the margins of the strips 18 and 20. The tape 28 is provided with upper and lower rows of buttons 32, and the tape 38 is formed with apertures 34 aligned with the buttons 32.

' The above disclosed joint between the opposed margins of the strips 18 and 20 may be effected manually. For this purpose, the cover parts 10 and 12 are assembled with the mattress body 26 as illustrated in. Figs. 25. Next, the tape 30 is manually introduced under the margin of the strip 18 and the tape 28 superposed on the margin of the strip 18, the upper buttons 32 being aligned with the upper apertures 34. Next, the buttons 32 are forced through the apertures 34 all around the sidewall or boxing of the mattress cover or case. Finally, the strips 18 and 20 are pulled closely together and held in this position while the lower buttons 32 are forced through the lower apertures 34. The assembly operation is then completed, yielding the finished mattress 2 shown in Fig. 1.

The seams 22 and 24 of the cover or case are easily sewed on an ordinary sewing machine in the sewing department of a mattress factory, and can without dilficulty be made with a pleasing tailored appearance. The joint between the strips 18 and 20 effected by the use of the tapes 28 and 30 is easily assembled and likewise presents a neat and attractive appearance.

Various modifications of the joint shown in Figs. 1 to 7 are possible. Thus, as shown in Fig. 8, the button carrying tape 28 may be placed inside the strips 18 and 20, with the buttons 32 projecting outwardly into the apertures 34 of the tape 38 which then runs along the outside of the strips 18 and 20.

Vent holes 36 and 38 may be provided, if desired, in the tapes 28 and 30. The apertures 36 and 38 are aligned as between the two tapes.

For best results, the margins of the strips 18 and 20 should be made of stretchable material, to permit some stretching and/or expansion around the buttons 32.

If desired, the buttons 32 may take the form of pointed studs having constricted necks, as disclosed hereinbelow and illustrated in Fig. 16. Then the tape 28 need not be apertured, and the margins of the strips 18 and 20 need not be stretchable since these margins as well as the tape 28 will then be pierced by the pointed studs.

Further, either of the tapes 28 and 30 may be split lengthwise to separate either the upper and lower rows of studs or buttons 32 or the upper and lower rows of apertures 34 in separate tapes. While the resulting joint is satisfactory, it is not quite as strong or neat as that shown in the drawings.

The tapes 28 and 30 may be made of any suitable material including fabrics, reinforced fabrics, synthetic resins, laminated resins and fabrics, and the like.

Reference is made to Fig. 6 as showing the relationship of the tapes 28 and 30 with the margins of the strips 18 and 20 before these parts are joined together. As shown, the tape 28 carries an upper and a lower row of spaced buttons 32 aligned with similarly arranged apertures 34 in the inner tape 30. The upper rows of spaced buttons 32 and therewith aligned apertures 34 are disposed on opposite sides of the margin of the strip 18, while the lower rows of spaced buttons 32 and apertures 34 aligned therewith are disposed on opposite sides of the margin of the strip 20. By forcing the upper series of buttons or studs 32 through the upper series of apertures 34 the margin of the strip 18 will be secured between the tapes 28 and 30. Similarly, by forcing the lower series of studs 32 through the lower series of apertures 34, the margin of the strip 20 will be secured between the tapes 28 and 30.

Reference is now made to Figs. 11 and i2 which show apparatus according to the present invention for assembling a cover on a mattress body. This apparatus includes a base 40, a fixed standard 42 projecting upwardly from the base and another standard 44 pivotally connected to the base 40 at 46. The standard 44 is provided with a horizontally projecting arm 48 perforated to receive therethrough a rod 50 having a lower end fixed to the base 48 and an upper end threaded to receive a wing nut 52. A coil spring 54 extends around the rod 50 between the base 40 and the arm 48. The rod 44 is swingable around the pivot 46 in the common plane of the bars 42 and 44. The coil spring 54 urges the bar 44 toward the bar 42. The adjustably set wing nut 52 limits the pivoting of the bar 44 towards the bar 42. At their upper ends, the bars 42 and 44 are provided with aligned journals 56 and 58 for aligned, opposed stud shafts 60 and 62 carrying at their ends rectangular plates 64 and 66 adapted to clamp therebetween the broad faces of a mattress body generally indicated at 70 and covered by cover parts indicated generally at 72 and 74 identical with the cover parts 10 and 12 illustrated in Figs. l-8. When so mounted between the plates 64 and 66, the mattress 70 may be rotated around its central transverse axis which is aligned with the stud shafts 60 and 62. In Fig. 11, the mattress 70 is shown in full lines in one position of rotation where its major axis extends horizontally and in broken lines in another position of rotation where its major axis extends vertically.

The device of Figs. 11 and 12 further includes an arm 76 having one end pivotally connected at 78 to a fixed support 80. A tape 82 is supplied from a roll 84 suitably supported or suspended above the mattress 70. Another tape 86 is supplied from a roll 88 suitably supported or suspended above the mattress 70.

As shown in Fig. 14, the free end of the arm 76 is bifurcated, the forked ends being indicated at 90 and 92. An electric motor 94 is supported on the forks 90 and 92 and serves to drive a roller 96 journalled in the free ends of the forks 90 and 92 by means of a belt 98 cooperating with appropriate pulleys on the shafts of the motor 94 and roller 96. Another roller 99 is journalled for free rotation in the forks 90 and 92 near the point of bifurcation.

The tape 82 passes underneath the driven roller 96 and the tape 86 passes underneath the idler roller 99.

The cover parts 72 and 74 include strips 100 and 102 defining sidewalls or boxing and formed at their edges, respectively, with enlarged beads 104 and 106. The strips 100 and 102 are joined to the body sheets of the cover parts 72 and 74 similarly to the cover parts 18 and 20 of Figs. 1-8.

The margins of the strips 100 and 102 are threaded through slots 108 and opening at the two edge faces of a fiat shoe generally indicated at 112. The bottom of each of the slots 108 and 110 is enlarged, so that when the margins of the strips 100 and 102 are threaded into the slots in question the beads 104 and 106 are received and retained in the enlarged bottom portions of these two slots. The guide or shoe 112 is appropriately and fixedly supported from the forks 90 and 92 of the arm 76 so that as the mattress 70 is rotated and the margins of the strips 100 and 102 are thereby caused to move through the slots 108 and 110 from left to right as viewed in Figs. 11 and 13, the margins and the beads 104 and 106 will be properly aligned and spaced from each other by the action of the guide 112. As shown in Figs. 15 and 18, the slots 108 and 110 in the guide 112 diverge from each other to the right and the guide member 112 curves upwardly, so that the right hand portion of the guide member 112 (which may be bifurcated) serves to spread apart and to lift the margins of the strips 100 and 102 to the right, as viewed in Figs. 13, 15 and 17 before these margins are brought together in closely spaced opposed relationship as illustrated at the section line in Fig. 15 and in Figs. 1820. At its front end the guide 112 is formed with vertical axial slots 114 and 116 communicating with the slots 108 and 110 to expose the margins of the strips 100 and 102 adjacent the beads 104 and 106.

The roller 96 contacts the two margins of the strips 100 and 102 immediately to the left of the guide 112. The tape 82 passes under the roller 96 and is thereby interposed between the latter and top margin surfaces of the strips 100 and 102. The tape 82 carries spaced parallel longitudinal rows of studs 118 having restricted necks 120 and pointed end portions formed with axial ribs and hence star-shaped in cross section. The two rows of studs 118 on the tape 82 are spaced apart so that the studs will enter the slots 114 and 116 in the guide member 112 as the tape 82 passes under the roller 96. The studs 118 are thereby caused to pierce the margins of the strips 100 and 102 inside the beads 104 and 106. To insure proper alignment of the tape 82 with the grooves 114 and 116, the tape may be guided by a shoe 122 projecting upwardly from the guide 112. This shoe is adapted to extend between the studs 118 and to align the studs 118 with the slots 114- and 116 in the guide 112.

The opposed margins of the strips 100 and 102 are joined neatly together by the tape 32 and tiy the studs 118 projecting therefrom. This joint is made stronger by including therewith the tape 86 disposed below the margins of the strips 100 and 102 and also pierced by the studs 118 of the tape 82. The tape 86 is formed with marginal beads 125 and 126. The guide member 112 includes a slot 128 formed in a shoe 130 integral with the shoe 112 and extending below and parallel with the slots 108 and 110. The slot 128 is enlarged at its two sides to receive and retain the beads 125 and 126. To the right, the guide shoe 130 curves upwardly so that the tape 86 can move from below the roller 99 into the open end of the slot 128. The shoe 130 extends to the left past the end of the guide member 112 and is formed with slots 132 and 134 aligned with the slots 114 and 116. Thus, the studs 118 of the tape 82 will pierce both the margins of the strips 100 and 102 and also the tape 86 extending below these margins.

It will be noted that the studs 118 of the tape 82 pierce the margins of the strips 100 and 102 While the latter are supported and retained in the slots 108 and 110 of the guide 112. The force required to effect this piercing of the strips 100 and 102 by the studs 118 is exerted by the roller 96. Similarly, the studs 118 of the tape 82 pierce the margins of the tape 86 while the latter is supported and retained in the slot 128 of the shoe 130. Again, the force exerted by the roller 96 effects this piercing. As shown, the strips 100 and 102 are backed up by the guide 112, and the tape 86 is backed up by the shoe 130 when the pressure of the roller 96 forces the studs 118 through the strips 100 and 102 and through the tape 86.

The edge beads 104 and 106 of the strips 100 and 102 and the edge beads 125 and 126 of the tape 86 serve to enable these structures to be guided and retained by the guides 112 and 130 into and in proper position for forming the above noted joint. Further, the beads 104 and 106 and 125 and 126 reinforce the joint, preventing transverse tearing of the strips and 102 and of the tape 86. Note that the studs 118 pierce the strips 100 and 102 and the tape 86 close the free margins'thereof, so that on transverse stressing of the joint, the material between the free margins of the strips and/or the tape and the studs would be easily torn if the above noted edge beads were not provided.

If desired, the tape 82 may be suitably reinforced along the lines of attachment thereof of the studs 118.

Many details may be varied without departing from the principles of this invention and it is therefore not my intention to limit the patent granted on this invention otherwise than necessitated by the scope of the appended claims.

The invention is claimed as follows:

1. A mattress cover comprising upper and lower parts, each part including a body sheet and a marginal strip, the strips of said two parts jointly defining a sidewall for said cover, a first tape underlapping the edges of said strips, a second tape overlapping the edges of said strips, and means passing through the edges of said strips and holding said tapes together.

2. A mattress cover according to claim 1 in which said means holding said tapes together comprises buttons fixed to one of said tapes.

3. A mattress cover according to claim 1 in which said means holding said tapes together comprises pointed studs fixed to one of said tapes and piercing the other tape.

4. A mattress cover according to claim 1 in which the edge of each marginal strip comprises a reinforcing head.

5. A mattress according to claim 1 in which said second tape is provided with reinforcing heads at its edges.

6. A mattress cover according to claim 5 in which the edge of each marginal strip comprises a reinforcing bead.

7. A mattress cover according to claim 1 in which said means for holding said tapes together comprises studs having restricted necks afiixed to one of said tapes and engaging the edges of said marginal strips and extending through the other of said tapes.

References Cited in the file of this patent UNITED STATES PATENTS 129,255 Saunders .iuly 16, 1872 1,094,588 OBrien Apr. 28, 1914 1,548,621 London Aug. 4, 1925 1,589,158 Hedison June 15, 1926 1,645,121 Stewart Oct. 11, 1927 1,939,324 Stafinsky Dec. 12, 1933 2,221,832 Cheney Nov. 19, 1940 2,538,396 Sutin Ian. 16, 1951 2,639,444 Monsabert May 26, 1953 2,824,351 Webb Feb. 25, 1958 FOREIGN PATENTS 13,219 Great Britain June 13, 1898 52,674 Switzerland Mar. 11, 1911 

